Yesterday our 2007 was filled at an ARCO which I had not used before. The pump kept shutting off every couple of gallons, as if it thought the tank was full. From the number of miles on the trip counter the car needed at least 8 gallons, so I just kept restarting the pump until it got up to 7, which was close enough. Today, 8 miles later, it was topped off at a Valero station we use frequently. It took 1.7 gallons more before the pump shut off. Now I know that under some circumstances there are filling problems on Gen 2's, but this wasn't a tank bladder issue. The nozzle on the first station was peculiar looking. In California all the nozzles have the usual metal tube and then around that and starting back several inches there is a rubber bellows which catches and recycles fumes. The ARCO pump had an unusually short tube projection, only around 2 inches, and the bellows was very stiff. The pump at the Valero had around 4" of protruding pipe and the bellows was not as stiff. So I think that odd ARCO nozzle was a problem. Coincidentally the previous fill was also at an ARCO, a brand we hardly ever use, and that nozzle was "normal" and there was no problem. The problem nozzle looked very much like the one on the right at this link Emco Wheaton Balance System Vapor Recovery Nozzles - John M. Ellsworth Co. Inc. whereas most nozzles look more like this one: https://www.jmesales.com/opw-14e-eco-enhanced-conventional-gasoline-nozzle-carb-certified I'm going to try to remember to change pumps the next time I see a short tube nozzle like that.
does the rubber compress on the short nozzle to make it the same length? overall, they look similar with less metal showing n the short one
Sometimes you can just encounter one dodgy filler nozzle, too, whatever its type. Did you try another pump at the same station?
Sometimes it's a fuel pressure issue... As in if every pump is pumping gas into a vehicle the pressure will be lower and sensor won't shut off prematurely. But go back to same station late at night when no one else is pumping and it might shut off often because the fuel pressure is way higher, making the sensor think your tank is full before it really is. I've found this is most common at new gas stations, especially ones in California.
I ran into this problem at a local Costco that had a strange filler nozzle of a design that I’d never seen before. Was a very short tube without bellows. Cut off almost immediately even though tank was down to two blips. Eventually I worked on it and it filled normally and too 9 gallons. Never had this problem before anywhere else.
I have run into that situation a few places, and it seems not related to the nozzle design. The solution for me has been to pump gas as slowly as possible so it doesn’t cut off.
I run into a similar issue with my GT3. I find that filling with the handle inverted (handle up vs down) generally seems to fix the issue. Not sure what the culprit actually is though.
That didn’t work for me. Slow or fast was still a problem. It was an odd nozzle design. Never saw it before. Had to hold it in place to get it to work. A real PiTA.
